Robust nose torque-limiting device

ABSTRACT

A torque-limiting driver is disclosed, having a handle, a body, a torque-limiting assembly and a work-piece engaging tip. The torque-limiting assembly includes an upper and lower shank that have a plurality of teeth circumferentially spaced. The teeth have a vertical face, an inclined face, and a flat peak. There is a spring for applying pressure across the upper and lower shank with multiple washers interposed between the lower shaft and spring. In some instances, there is a round-square drive with arched catches having preselected radii to assure operation over certain cycles at selected torque and to reduce nose cone damage and breakage at a predetermined measurement of inch-pounds of torque.

RELATED APPLICATION

This application claims the benefit of and priority to U.S. Provisional Application Ser. No. 61/463,548 with a filing date of Feb. 18, 2011 which is incorporated by reference as if fully set forth herein in its entirety.

BACKGROUND

1. Field

This disclosure relates to a medical use driver tool and, in particular, to a torque-limiting driver that disengages at a predefined torque limit.

2. General Background

Torque-limiting drivers are widely used throughout the medical industry. These torque-limiting drivers have a factory pre-set torque to ensure the accuracy and toughness required to meet a demanding surgical environment.

The medical industry has made use of both reusable and disposable torque-limiting drivers. In a surgical context, there is little room for error and these drivers must impart a precise amount of torque.

Reusable drivers require constant recalibration to ensure that the driver is imparting the precise amount of torque. Recalibration is a cumbersome task but must be done routinely.

Disposable drivers are an easy to use and reliable alternative to the reusable drivers. Typically, a medical device such as an implant, for example, is packaged with a disposable driver designed to the implant's specifications. Once the driver has been used, it can be discarded. Thus, a surgeon can have complete confidence that the disposable driver, packaged with an implant, will impart the precise amount of torque. Typically, the torque requirement is different for different operations and for different implants. For example, applications may include those in the field of orthopedic surgery, construction and emplacement of implants, etc.

These disposable drivers have been used for low torque applications. The standard torque values in these applications typically range from 4 to 20 inch-ounces. It has, however, been a challenge to develop a reliable disposable driver capable of imparting higher torques for larger applications.

DISCLOSURE

Torque is a measure of how much force acting on an object causes that object to rotate. In the case of a driver and a fastener, this measurement can be calculated mathematically in terms of the cross product of specific vectors: τ=r×F

Where r is the vector representing the distance and direction from an axis of a fastener to a point where the force is applied and F is the force vector acting on the driver.

Torque has dimensions of force times distance and the SI unit of torque is the Newton meter (N m). The joule, which is the SI unit for energy or work, is also defined as an N m, but this unit is not used for torque. Since energy can be thought of as the result of force times distance, energy is always a scalar whereas torque is force cross-distance and so is a vector-valued quantity. Other non-SI units of torque include pound-force-feet, foot-pounds-force, ounce-force-inches, meter-kilograms-force, inch-ounces or inch pounds.

A disposable torque-limiting driver, in accordance with the present disclosure, has a handle, a cylindrical body and a work-piece engaging tip. Within the cylindrical body there is a torque-limiting assembly. The torque-limiting assembly includes an upper cylindrical shank and a lower cylindrical shank. The upper cylindrical shank and the lower cylindrical shank have a plurality of teeth. The teeth have a vertical face, an inclined face and a substantially flat peak. The inclined face is defined by a first radius of curvature that transitions to the substantially flat peak. The teeth are spaced circumferentially and spiral around the upper cylindrical shank and a lower cylindrical shank. There is a spring for applying pressure across the upper cylindrical shank and the lower cylindrical shank. The teeth of the upper cylindrical shank and the lower cylindrical shank engage for relative rotation when the handle is turned and disengage when a predetermined value of torque is exceeded.

Smooth repeat operation is encouraged with specific dual bearing surfaces.

A round square implementation provides a range of use over predetermined cycles of up to almost 150 inch pounds rotations without cracking the plastic nose cone. In some instances a square engagement with radiuses corners having radii between about 0.1482 and about 0.1638 inches are optimal. In some instances a square engagement with radiuses corners having radii between about 0.1292304 and about 0.1716 inches are optimal. In other instances a square engagement with radiuses corners having radii is between about 0.1266 and about 0.1794 inches is optimal.

A torque driver capable of transferring high torque with a spring having a spring constant (also referred to as a force constant) which exerts a greater force in an initial (rest) state via a multiple washer bearing interface. A single washer interface with end of spring may have a tendency to grip or bind spring and washer; a multiple washer interface provides a bearing surface between spring and remote second washer. Elimination or reduction of binding or gripping between washer and spring may provide a smoother rotation.

DRAWINGS

FIG. 1 is a perspective view of a driver in accordance with the present disclosure.

FIG. 2 is an exploded view of a driver in accordance with the present disclosure.

FIG. 3 is a vertical cross sectional view of a driver in accordance with the present disclosure.

FIG. 4 is a horizontal cross sectional view of a driver in accordance with the present disclosure.

FIG. 5 is a perspective view of an upper shank in accordance with the present disclosure.

FIG. 6 is a profile of a tooth from a clutch assembly in accordance with the present disclosure.

FIG. 7 is a perspective view of the teeth from a clutch assembly in accordance with the present disclosure.

FIG. 8 is a top view of the teeth from a clutch assembly in accordance with the present disclosure.

FIG. 9 is a partial exploded view of the nose region of FIG. 2.

FIG. 10 is an exploded view of a driver in accordance with the present disclosure.

FIG. 11 is shaft in accordance with the present disclosure.

FIG. 12 is a cross sectional view at line A-A of FIG. 11 in accordance with the present disclosure.

FIG. 13 is a front view of the nose of FIG. 10 in accordance with the present disclosure.

FIGS. 14A through 14C show comparative test results with various driver geometries.

FIGS. 15A and 15B show comparative test results of round square configurations with about 13 revolutions, using a single washer and about 11 revolutions using two adjacent washers.

While the specification concludes with claims defining the features of the present disclosure that are regarded as novel, it is believed that the present disclosure's teachings will be better understood from a consideration of the following description in conjunction with the appendices, figures, in which like reference numerals are carried forward. All descriptions and callouts in the Figures are hereby incorporated by this reference as if fully set forth herein.

FURTHER DISCLOSURE

Referring to FIGS. 1-9, there is a torque-limiting driver 100. The torque-limiting driver 100 has a generally T-shaped handle. The T-shaped handle includes arms 4 at one end an axially extending generally hollow cylindrical body 6, a cap 2 that covers the same end of the T-shaped handle and a cylindrical end 18 opposite the T-shaped handle on the cylindrical body 6. The cap 2 may be snap-fitted to the cylindrical body 6, or may be welded, or attached by any equivalent thereof and the body is preferably molded from a plastic or other economical equivalents.

At the cylindrical end 18, there is a lower shank 700 that has and annularly tapering body and a nose cone 8 along its length. The lower shank 700 may have a plurality of support flanges 10 that add strength while saving material. At one end, the lower shank 700 tapers to a drive socket 9 at the end of the nose cone 8 molded to engage a shaft 14. The shaft 14 maybe substantially linear with a proximal end that mates with said drive socket. The shaft 14 may be hexagonal or cylindrical in transverse cross-sectional shape and is provided, at one end, with a work piece-engaging distal tip 12, adapted for engagement with an associated work-piece, such as a fastener or the like. The work piece-engaging distal tip 12 is shown to be a hex wrench, but could be a screwdriver, wrench, or any other tool or medical tool arrangement. At an opposite end, the lower shank 700 has a plurality of teeth 82 arranged in a crown gear formation, a circumferential rim 31 extending radially outwardly and an internally threaded axial bore.

FIG. 2 is an exploded view of the driver 100. Inside the cylindrical body 6 a clutch assembly is disposed. The clutch assembly includes an upper shank 800 for forcibly engaging the lower shank 700. The upper shank 800 has a bottom face that has teeth 82 arranged in a crown gear formation and an annular flange or circumferential rim 83 extending radially outwardly. Shown on FIG. 5, the upper shank 800 includes an annular body or outer cylindrical shank 84, an axial bore 92 through an inner shank 86. The inner shank 86 and outer shank 84 are connected via inner supports 88, leaving the upper shank 800 substantially hollow with internal spaces 90 on a top face.

The upper shank 800 also includes at least one recess 80 on the side of the outer shank. The recess 80 is provided as a cylindrical cut, relief or recess into the side of the outer shank and maybe provided as a square or rectangular cut or the cut may have a slanted side or sides relative to the axis of the upper shank 800 as shown in FIG. 2.

In assembly, the shaft 14 at its proximal end forms drive connection 16 which is received into the drive socket 9 of the lower shank 700. A washer (not detailed in the implementation) may be provided between the circumferential rim 31 of the lower shank 700 and a circumferential flange 30 extending radially inward within the hollow of the cylindrical body 6. Alternatively, the circumferential rim 31 of the lower shank 700 may be provided flush against circumferential flange 30 of the cylindrical body 6.

Drive socket 9 and the connection 16 are shown having corresponding cross sectional shape. In this implementation the hexagonal shape provides multiple stops and surface area to facilitate consistent operation over the anticipated use profile without significant wiggle or loosening of the shaft 14 from the drive socket 9. A use profile includes, but is not limited to, such factors as required lbf (load) or inch pounds of torque, number of uses, cycle time, material nose cone 8 is formed of and material forming shaft 14.

The opposite side of the circumferential flange 30 receives the circumferential rim 83 of the upper shank 800 allowing the teeth 82 of the lower shank 700 to engage the teeth 82 of the upper shank 800 when a torque is applied.

Integrally formed within the cylindrical body 6, a protrusion 85 mates with the recess 80 of the upper shank 800. FIG. 3 and FIG. 4 are cross sectional views that best illustrate the protrusion 85 in relation with the recess 80. The protrusion 85 extends inward in a radial fashion and has a length along the axis of the cylindrical body 6 for relative moveable engagement within the recess 80. This engagement provides a locking mechanism of the shaft 14 relative to the T-shaped handle via the upper shank when pressure is applied across the lower shank 700 and the upper shank 80. The recess 80 is provided circumferentially wider than the protrusion 85 for allowing the cylindrical body 6 and the T-shaped handle to rotate in reverse a predetermined distance from a locked position without subsequent reverse rotation of the work piece-engaging tip 12. Thus, the at least one recess 80 and at least one protrusion 85 lock the T-shaped in one direction providing the necessary torque to drive a fastener and allow for a predetermined amount of reverse rotation before unscrewing the fastener.

Force is applied across the lower shank 700 and the upper shank 800 via a spring 22 within the cylindrical body 6. Inside the cylindrical body 6, shown in FIG. 2 and FIG. 5, a washer 20 is provided between the upper shank 800 and the spring 22. The washer transfers pressure from the spring 22 over the top face of the upper shank 800. At an end of the spring 22 opposite the upper shank 800, a cup washer 24 and a locking fastener 26 hold the spring 22 in a compressed state. The locking fastener 26A has a fastener head 26B and has a threading 28 that engages a complementary threading within an axial bore 72 of the lower shank 700. Thus, imparting pressure between the respective teeth 82 of the lower shank 700 and the upper shank 800. The spring 22 and the locking fastener 26A provide the proper tensioning and biasing for the clutch assembly and, generally, the locking fastener 26A is adjustable to provide proper tension and calibration.

Formed on the top face of the lower shank 700 and the bottom face of the upper shank 800 are the plurality of teeth 82 that forcibly engage to impart torque from the T-shaped handle to the work piece when a torque is applied. Referring to FIGS. 6-7, tooth 82 has an inclined face 66 that smoothly transitions to a substantially flat peak 60, via a first radius of curvature 64. The substantially flat peak 60 subsequently transitions smoothly, via a second radius of curvature, to a vertical face 68 that is substantially parallel to the axis of the lower shank 700 and the upper shank 800. The first radius of curvature is typically much larger than the second radius of curvature.

Experimental results have shown that a tooth having an inclined face that smoothly transitions to a substantially flat face is capable of imparting a substantial increase in torque to a fastener. In one experiment, a ten-fold increase in torque was observed. This increase in torque is due to the frictional forces associated with the smoothly transitioning curve of an inclined face 66 of the teeth 82.

In a simplified example, when two uniform inclines are frictionally engaged, only one static force, having a single coefficient of static force, is acting against the relative movement of the two inclines. However, when the two inclines are not uniform, more than one coefficient of static force can be observed, thus resulting in a higher disinclination to movement.

The teeth 82 are circumferentially spaced in a crown gear formation of the top face and bottom face of the lower shank 700 and the upper shank 800 respectively. The teeth 82 are also preferably configured in a spiral formation, best shown in FIG. 7. Each face of the lower shank 700 and the upper shank 800 has an inner radius and an outer radius and the teeth 82 spiral around the inner radius resulting in a larger tooth detail when viewing the tooth from the outer radius relative to the tooth detail when viewing the tooth from the inner radius. The spiral configuration of the teeth 82 can also be defined as having a longer inclined face 66 at the edge of the tooth on or near the outer radius relative to the inclined face 66 at the edge of the tooth on or near the inner radius of the lower shank 700 and the upper shank 800. Results have shown that teeth arranged in a spiral configuration provide an increased reliability and precision in torque consistency when compared to their non-spiral counterparts.

The substantially flat peak 60 of the teeth 82 can be as wide at the inner radius as they are at the outer radius. Alternatively, the substantially flat peak 60 may be wider at the outer radius and taper toward the inner radius.

The vertical faces 68 of the teeth 82 of the lower shank 700 and the upper shank 800 respectively engage when a torque is applied to prevent relative rotation of the lower shank 700 and the upper shank 800 in one direction. The inclined faces 66 engage to accommodate relative rotation of the lower shank 700 and the upper shank 800 in an opposite direction.

The extent to which the locking screw 26 is threaded into the axial bore 72 of the lower shank 700 controls the amount of compression or preload on the spring 22 which, subsequently, controls the limiting torque required to effect relative rotation of the lower shank 700 and the upper shank 800. If the locking screw 26 is threaded deeply into the lower shank 700, a higher torque will be required to disengage the teeth 82 of the lower shank 700 and the upper shank 800 than if locking screw 26 was threaded into the lower shank 700 relatively shallow.

Thus, when the driver 100 is rotated in one direction, the shaft 14 will rotate with the cylindrical body 6 and T-shaped handle until a predetermined torque is reached. When this predetermined torque is reached, a biasing force exerted by the spring 22 is overcome, allowing an inclined face 66 of the upper shank 800 to slide up a respective inclined face 66 of the lower shank 700, subsequently snapping the teeth 82 of the lower shank 700 into engagement behind a next tooth of the upper shank 800. This snapping sound is typically an audible indication to a user that a predetermined torque has been reached.

When a force beyond the required value of torque is reached, the teeth of the lower shank 700 and the upper shank 800 will continue to disengage, resulting in rotation of the handle with no further rotation of the work piece-engaging tip 12. Thus, the handle will continue to rotate, disengaging the teeth 82 with every rotational movement that will not impart continued force beyond a predefined threshold to the fastener.

When the driver 100 is rotated in the opposite direction, the T-shaped handle rotates in reverse a predetermined distance from a locked position without subsequent reverse rotation of the work piece-engaging tip 12. However, when the protrusion 85 travels the predetermined distance and locks against the opposite end of the recess 80, the driver 100 will operate as a standard driver with no torque-limiting feature since the engaging vertical face 68 will force relative rotation of the lower shank 700 and the upper shank 800 in the opposite direction without any torque-limiting feature.

The disposable torque-limiting driver of the present disclosure preferably imparts torques on the order of about 1 ounce inch to 100 inch ounces. Torques of this magnitude can be utilized in precision high torque environments such as the installation of dental, joint, vertebral implants and the like. Typically, the torque requirement is different for different operations and for different implants. Therefore, in some instances, the torques maybe around 1 inch pounds. In other instances, the predetermined torque maybe at least 30 inch pounds and yet other instances, at least 60 inch pounds, depending on an implant's specifications.

In some instances, a torque-limiting driver, such as driver 100, may be prepackaged with an implant provided for one-time use. Such an instance insures that the driver imparts the required amount of torque and has not been worn in or dulled by overuse.

In other instances, the driver 100 may be reusable. The shaft 14 may be interchangeably fixed relative to the nose cone 8 for the accommodation of multiple work piece engaging tips 12. It is also to be appreciated that the handle of the driver is not limited to a T-shape and may be provided in any other suitable configuration.

Referring to FIGS. 10-13, there is a torque-limiting driver 200. The torque-limiting driver 200 generally includes a handle. The handle 2 includes arms 4 at one end an axially extending generally hollow cylindrical body 6, a cap 2 that covers the same end of the T-shaped handle and a cylindrical end 18 opposite the T-shaped handle on the cylindrical body 6. The cap 2 may be snap-fitted to the cylindrical body 6, or may be welded, or attached by any equivalent thereof and the body is preferably molded from a plastic or other economical equivalents.

At the cylindrical end 18, there is a lower shank 700 that has and annularly tapering body and a nose cone 8 along its length. The lower shank 700 may have a plurality of support flanges 10 that add strength while saving material. At one end, the lower shank 700 tapers to an axial drive socket 9′ at the end of the nose cone 8 molded of a non-metal material such as a plastic, polymer, resin including but not limited to (plastics, resins, polymers, imides, fluoropolymers, thermoplastic polymers, thermosetting plastics, and the like as well as blends or mixtures thereof) to engage a shaft 14. The shaft 14 drive connection 16′ is rounded square in transverse cross-sectional shape (see FIGS. 11 and 12) and is provided, at one end, with a work piece-engaging tip 12. The shaft 14 is substantially round in cross section. The drive connection 16′ is generally square but has rounded corners 95 connecting substantially flat sides 97. Testing as illustrated in FIGS. 14A through 14C demonstrated that eliminating hard corners between the walls of the square cross section drive connection 16′ to the drive socket 9′ of lower shank 700 forming a “Round Square” interface more evenly distributes the force applied thereto and substantially reduces deformation, bending, breaking, and/or cracking of the non-metal nose cone 8 region of the drive socket 9′ at high load (lbf) and/or inch pounds over time as compared to other geometries such as triangular or hexagonal of drive socket and drive connection as shown in FIG. 14B.

In some implementations, the round square implementation provides a range of use over predetermined cycles of up to almost 150 inch pounds. In some implementations, the round square implementation provides a range of use over predetermined cycles of between at least about 10 and about 140 inch pounds. In addition testing has shown that the round square cross section of the drive connection 16′ and drive socket 9′ have a more robust connection, compared to, triangle or hexagonal and does not “strip”, deform or spin in the drive socket as readily as shafts and drive sockets with hexagonal or triangular cross sections. Within the corresponding drive socket 9′, as shown in FIG. 13 the radii of about 0.156 inches of the catches 99 correspond to the rounded corners 95 of the drive connection 16′. Within the drive socket 9′ of the nose 8 is generally square but has rounded corners 95 connecting substantially flat sides 97. The drive socket 9′ in cross section has four substantially planar walls; four arched corners (the catches 99) and each catch 99 with a preselected radius to distribute the load caused by turning shaft 14 at a predetermined torque over a predetermined number of rotations without cracking the plastic nose cone 8 material that surrounds the drive socket to a point of failure. The optimal range of radii to achieve even (as in even load) repetitive rotations can be selected to correspond to the torque requirements of a particular driver. In some implementations the optimal radii is between about 0.1482 and about 0.1638 inches. In some implementations the optimal radii is between about 0.1292304 and about 0.1716 inches. In some implementations the optimal radii is between about 0.1266 and about 0.1794 inches.

At an opposite end, the lower shank 700 has a plurality of teeth arranged in a crown gear formation, a circumferential rim 31 extending radially outwardly and an internally threaded fastener bore.

FIG. 10 is an exploded view of the driver 200. Inside the cylindrical body 6 a clutch assembly is disposed. The clutch assembly includes an upper shank 800 for forcibly engaging the lower shank 700. The upper shank 800 has a bottom face that has teeth arranged in a crown gear formation and an annular flange or circumferential rim extending radially outwardly.

According to aspects of one or more exemplary implementations, force is applied across lower shank 700 and upper shank 800 via spring 22 within cylindrical body 6. Inside cylindrical body 6, shown in FIG. 10 washer 20 and washer 21 are provided between upper shank 800 and spring 22. Washer 20 and washer 21 transfer pressure from spring 22 over the top face of upper shank 800. At an end of spring 22 opposite upper shank 800, shoulder washer 25 and a fastener 26A fastener head 26B hold spring 22 in a relatively compressed state. Washer 23 between shoulder washer 26 and spring 22 to facilitate relative rotation of fastener head 26 and spring 22. The fastener is threaded 28 and said threads engage with the internally threaded fastener bore inside of the lower shank 700.

According to aspects of one or more exemplary implementations, driver 200 capable of transferring higher torque may be provided with spring 22 having a greater spring constant (i.e., force constant) or otherwise be calibrated with spring 22 exerting greater forces in an initial (rest) state. As demonstrated via test results shown in FIGS. 15A and 15 B, adding a more robust spring 22 may be used when also adding washer 20 and washer 21 at the end of said spring nearest said upper shank 800, in such instance although spring 22 may have a tendency to grip relative to washer 21 the bearing surface between washer 20 and washer 21 unexpectedly provided a smoother rotation. FIGS. 15A and 15B provide test results showing that an increased load without extensive binding may be achieved when using a multi-washer (21 and 20) system, as opposed to a single washer (20 or 21). In some implementations, disclosed is a drive socket 9′ which in cross section has four substantially planar walls; four arched corners (the catches 99) and each catch 99 with a preselected radius to distribute the load caused by turning shaft 14 at a predetermined torque over a predetermined number of rotations without cracking or otherwise damaging the non-metal nose cone 8 material that surrounds the drive socket to a point of failure. A more robust spring 22 produces pressures that may be damaging to the device. Such a spring increases the probability of a friction grip relative to washer 21. Provision of additional washer 20 preserves at least one free-spinning structure between the distal end of the spring 22 and upper shank 800. Moreover, by adding at the proximal end of the spring the shoulder washer 27 and washer 25 to replace the cup washer 24, testing shows that a cup washer, such as that shown in FIGS. 2 and 3 may over time deform, indent, bend, break fail or partially fail from use and the pressure excreted thereon by the fastener head 26B against the cup washer 24. The shoulder washer 27 fastener head 26B interaction reduce such failure or deformation and further provides more robust spring forces against the washers.

In assembly, drive connection 16′ of shaft 14 is received into drive socket 9′ of lower shank 700. Washer 32 maybe provided between circumferential rim 31 of lower shank 700 and circumferential flange 30 extending radially inward within the hollow of cylindrical body 6. Washer 32 may be of a polymer or other material having low coefficient of friction. Alternatively, circumferential rim 31 of lower shank 700 may be provided flush against circumferential flange 30 of cylindrical body 6.

While the method and agent have been described in terms of what are presently considered to be the most practical and preferred implementations, it is to be understood that the disclosure need not be limited to the disclosed implementations. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all implementations of the following claims.

It should also be understood that a variety of changes may be made without departing from the essence of the disclosure. Such changes are also implicitly included in the description. They still fall within the scope of this disclosure. It should be understood that this disclosure is intended to yield a patent covering numerous aspects of the disclosure both independently and as an overall system and in both method and apparatus modes.

Further, each of the various elements of the disclosure and claims may also be achieved in a variety of manners. This disclosure should be understood to encompass each such variation, be it a variation of an implementation of any apparatus implementation, a method or process implementation, or even merely a variation of any element of these.

Particularly, it should be understood that as the disclosure relates to elements of the disclosure, the words for each element may be expressed by equivalent apparatus terms or method terms—even if only the function or result is the same.

Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this disclosure is entitled.

It should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action.

Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates.

Any patents, publications, or other references mentioned in this application for patent are hereby incorporated by reference. In addition, as to each term used it should be understood that unless its utilization in this application is inconsistent with such interpretation, common dictionary definitions should be understood as incorporated for each term and all definitions, alternative terms, and synonyms such as contained in at least one of a standard technical dictionary recognized by artisans and the Random House Webster's Unabridged Dictionary, latest edition are hereby incorporated by reference.

Finally, all referenced listed in the Information Disclosure Statement or other information statement filed with the application are hereby appended and hereby incorporated by reference; however, as to each of the above, to the extent that such information or statements incorporated by reference might be considered inconsistent with the patenting of this/these disclosure(s), such statements are expressly not to be considered as made by the applicant(s).

In this regard it should be understood that for practical reasons and so as to avoid adding potentially hundreds of claims, the applicant has presented claims with initial dependencies only.

Support should be understood to exist to the degree required under new matter laws—including but not limited to United States Patent Law 35 USC 132 or other such laws—to permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept.

To the extent that insubstantial substitutes are made, to the extent that the applicant did not in fact draft any claim so as to literally encompass any particular implementation, and to the extent otherwise applicable, the applicant should not be understood to have in any way intended to or actually relinquished such coverage as the applicant simply may not have been able to anticipate all eventualities; one skilled in the art, should not be reasonably expected to have drafted a claim that would have literally encompassed such alternative implementations.

Further, the use of the transitional phrase “comprising” is used to maintain the “open-end” claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term “compromise” or variations such as “comprises” or “comprising”, are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.

Such terms should be interpreted in their most expansive forms so as to afford the applicant the broadest coverage legally permissible.

The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants' contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art. 

The invention claimed is:
 1. A disposable torque-limiting driver comprising: a handle and an axially extending cylindrical body; a torque-limiting assembly within the axially extending cylindrical body, the assembly comprising; an upper cylindrical shank; a lower cylindrical shank; wherein the upper cylindrical shank and the lower cylindrical shank have a plurality of teeth and an axial bore, the teeth have a vertical face, an inclined face and a flat peak, wherein the inclined face is defined by a first radius of curvature that transitions to the flat peak and wherein the teeth spiral around the axial bore; a spring for applying pressure across the upper cylindrical shank and the lower cylindrical shank, wherein the teeth of the upper cylindrical shank and the lower cylindrical shank engage for relative rotation, and wherein the teeth disengage when a predetermined value of torque is exceeded; a locking screw inserted through said spring and threaded to mate with the lower cylindrical shank through the upper cylindrical shank; a plastic nose cone at a distal end of the lower cylindrical shank with a cavity forming a drive socket in the nose cone comprising; four planar walls within the cavity; and, four arched corners within the cavity each forming a catch with a radius sufficient to distribute the force caused by turning a shaft at a torque having a value lower than the predetermined torque at which the teeth disengage without cracking the plastic nose cone over a plurality of rotations interposed between said planar walls, wherein each of the four arched corners is between two orthogonal planar walls.
 2. The disposable torque-limiting driver of claim 1 further comprising a removable shaft with a proximal end corresponding in cross section to said drive socket.
 3. The disposable torque-limiting driver of claim 2 further comprising a work-piece engaging tip connected to a distal end of said shaft.
 4. The disposable torque-limiting driver of claim 3 wherein said drive socket accepts a predetermined torque without disabling the drive socket due to breakage.
 5. The disposable torque-limiting driver of claim 2 wherein said drive socket accepts a predetermined torque without disabling the drive socket due to breakage.
 6. The disposable torque-limiting driver of claim 2, wherein the predetermined torque is at least 90 inch pounds.
 7. The disposable torque-limiting driver of claim 2, wherein the predetermined torque is at least 120 inch pounds.
 8. The disposable torque-limiting driver of claim 2, wherein the predetermined torque is between about 60 pounds and about 130 pounds.
 9. The disposable torque-limiting driver of claim 2, wherein the radius is between 0.1482 and 0.1638 inches.
 10. The disposable torque-limiting driver of claim 2, wherein the radius is between 0.1292304 and 0.1716 inches.
 11. The disposable torque-limiting driver of claim 2, wherein the radius is between 0.1266 and 0.1794 inches.
 12. The disposable torque-limiting driver of claim 2 further comprising a tip connected to a distal end of said shaft.
 13. A method of reducing plastic nose cone breakage of a disposable torque-limiting driver operating at a selected torque, the method comprising: applying a preselected amount of torque to a tool fitted to a torque limiting device via a square drive socket of a plastic nose cone; said drive socket having been formed of four planar walls and interposed between each wall is an arched corner catch each with a radius sufficient to distribute the force caused by turning a shaft at the predetermined torque without cracking the plastic nose cone over a plurality of cycles: and, wherein each wall is parallel to the opposing wall and orthogonal to the adjacent wall.
 14. The method of claim 13, wherein the predetermined torque is at least 60 inch pounds.
 15. The method of claim 14 the predetermined torque is between about 105 and about 110 inch pounds.
 16. The method of claim 15 wherein the nose cone continues to function within the predetermined torque range for at least about 105 cycles.
 17. The method of claim 16 wherein the nose cone continues to function within the predetermined torque range for at least about 135 cycles.
 18. The method of claim 13 wherein the predetermined torque is between about 75 and about 85 inch pounds.
 19. The method of claim 18 wherein the nose cone continues to function within the predetermined torque range for at least about 108 cycles.
 20. The method of claim 18 wherein the nose cone continues to function within the predetermined torque range for at least about 138 cycles.
 21. The method of claim 13 the predetermined torque is above about 120 inch pounds.
 22. The method of claim 21 wherein the nose cone continues to function within the predetermined torque range for at least about 105 cycles. 